PSM w ABS

ABS RULES FOR SURVEY AFTER CONSTRUCTION . 2014 521

P A R T Section 14: Surveys Based on Preventative Maintenance Techniques

7 A P P E N D I X

S E C T I O N 14 Surveys Based on Preventative Maintenance

Techniques (1 July 2012)

1 General

The intent of a Preventative Maintenance Program is for owners/operators to maintain their vessels with updated machinery maintenance practices, which may increase a vessels reliability and/or operational availability. While a Surveyor may allow a reduction in the amount of covered equipment being opened for crediting towards Special Continuous Survey of Machinery (CMS), provided it is enrolled in a Preventative Maintenance Program (PMP), operational testing may be increased.

The following are procedures and conditions under which a properly conducted preventative maintenance plan may be credited as satisfying the requirements of Special Continuous Survey of Machinery. No preventative maintenance program supersedes the judgment of an ABS Surveyor, nor does it waive an ABS Surveyor(s) attendance for damage, overhaul of main engines, generator engines, steering gears, general insulation condition and resistance tests, electrical devices functional tests, reduction gear teeth examinations, hydrostatic tests of pressure vessels, tests and verification of safety devices such as relief valves, overspeed trips, emergency shut-offs, low-oil pressure trips, etc., as required by the ABS Rules for Building and Classing Steel Vessels, including the ABS Rules for Survey After Construction (Part 7). The reference to an ABS Recognized Condition Monitoring Company refers to those companies whom ABS has identified as an External Specialist. For additional requirements, refer to 7-A-14/19 of this Appendix.

1.1 Survey and Maintenance Intervals

Maintenance is to be carried out on the basis of intervals between overhauls recommended by manufacturers, documented operators experience and/or a condition monitoring system, where fitted. In general, the intervals for the Preventative Maintenance Program are not to exceed those specified for Special Continuous Survey of Machinery (CMS). However, for components where the maintenance is based on running hours or number of cycles, longer intervals may be accepted as long as the intervals are based on the manufacturers recommendations. In addition, if an approved PMP is in effect, the opening of individual items of equipment may not be required during the CMS cycle, based on satisfactory results within the program.

1.2 Definitions

i) Special Continuous Survey of Machinery (CMS) A program in which the total number of survey items is arranged in order to provide for survey of approximately 20% of the machinery each year during a five-year period.

ii) Preventative Maintenance Program (PMP) A program that consists of Planned Maintenance and/or Condition Monitoring plans.

a) Planned Maintenance (PM) A maintenance plan which uses time-based inspection, part replacement and/or overhauls in an effort to prevent equipment failures. Timing can be based on calendar days, cycles counter or equipment running hours. Such schedules are generally established by the machinery manufacturer and include lubrication servicing; filter, bearing and seal replacements; as well as major overhaul.

b) Condition Monitoring (CM) The use of various technologies to determine the condition of equipment, at a specific moment in time, using minimal or non-invasive means. Common tools used in condition monitoring are vibration analysis, oil analysis, ferrography, thermography, electric current wave form analysis and boroscopic examination. Supplemental technologies, such as demodulation, ultrasonic analysis, shock-pulse, spike-energy, HFD, etc., for roller bearing element condition monitoring, may be used in addition to vibration analysis.

Part 7 Rules for Survey After Construction Appendix Section 14 Surveys Based on Preventative Maintenance Techniques 7-A-14

522 ABS RULES FOR SURVEY AFTER CONSTRUCTION . 2014

iii) Condition Based Maintenance (CBM) A maintenance plan, conducted on a frequent or real-time

basis, which is based on the use of Condition Monitoring to determine when part replacement or

other corrective action is required. This process involves establishing a baseline and operating

parameters, then frequently monitoring the machine and comparing any changes in operating

conditions to the baseline. Repairs or replacement of parts are carried out before the machinery

fails based upon the use of the tools prescribed for CM.

iv) Reliability Centered Maintenance (RCM) RCM is a process that is used to determine the most

effective approach to maintenance. It involves identifying actions that when taken will reduce the

probability of failure and which actions are most cost effective. ABS has developed a maintenance

program which uses RCM analysis of installed equipment to develop a Preventative Maintenance

Program (PMP), a spare parts holdings list and includes a sustainment plan.

a) Reactive Maintenance A RCM maintenance strategy in which equipment is run until

failure before corrective action is taken. This is useful for items which are low-cost and

have no impact on operational, environmental or safety concerns as a result of failure.

b) One-Time Change A RCM maintenance strategy in which equipment or systems, that have

been determined to present an unacceptable level of risk and have no potential mitigations,

are replaced or significantly altered in order to provide an acceptable level of risk.

1.3 Optional Notation (2014)

An optional notation can be added to the Record indicating compliance with the Preventative Maintenance

Program on one or more pieces of equipment. The PMP notation indicates less than 50%, and the PMP+ notation indicates 50% or greater of all classed equipment is enrolled into this program.

3 Program Requirements

For a Preventative Maintenance Program to be accepted in lieu of a conventional Special Continuous Survey

of Machinery, the following conditions must be met:

3.1 Age of Vessel

There is no limit on the age of a vessel when entered into the program. However, an existing vessel

applying for entrance into the program will be subject to a review of the vessels Survey Status records to

ascertain the historical performance of the machinery which could affect the Preventative Maintenance

Program. Provided there are no historical problems related to the maintenance of the machinery, the vessel

will be considered eligible.

3.3 Surveys (2014)

Surveys related to the vessel are to be up-to-date, without outstanding recommendations which would

affect the Preventative Maintenance Program. The machinery in the program is to be on a Special Continuous

Survey of Machinery (CMS) cycle.

If the vessel is not on CMS, the Owner is to be advised that the vessel is to be entered in CMS. For machinery

for which an outstanding recommendation exists, confirmation is to be made that repairs have been performed,

or if repairs have not been performed, the Owner is to be notified that an outstanding recommendation exists.

The PMP notation can be applied to a vessel without an AMS notation with permanently installed machinery enrolled in either an approved PM, CM, or RCM plan. Vessels without an AMS notation will not be required to have the subject machinery on CMS, instead machinery will be credited in conjunction with the vessels

Special Periodical Survey of Hull (SSH). However, all other requirements of the PMP notation are to be complied with, including but not limited to the submission of an annual report to the attending Surveyor, as

detailed in 7-A-14/9.3 and maintenance of the required onboard documentation, as detailed in 7-A-14/11.

Any machinery items not covered by the Preventative Maintenance Program are to be surveyed and credited

in the usual way.



3.5 Damages

There is to be no record of unrepaired damage to the vessel or its machinery which would affect the vessels

ability to participate in the Preventative Maintenance Program.

3.7 Computerized Maintenance Management Systems

The activities of the Preventative Maintenance Program are to be programmed into the Computerized

Maintenance Management System (CMMS) and the history of all maintenance tasks are to be recorded and

stored in the CMMS by the operators/owners. These systems must include back-up devices, such as removable

hard drives, thumb drives, CD-ROMs or remote on-line back-up systems and are updated at regular intervals.

Details of the system are to be reviewed by the attending Surveyor during the implementation survey.

5 Program Description

5.1 General

To enroll equipment items into Planned Maintenance (PM) [See 7-A-14/13.5.1(a)], a comprehensive plan

is to be submitted to the attending ABS Survey Office for review prior to conducting an implementation survey.

To enroll equipment items into Condition Monitoring (CM), the documentation required by 7-A-14/15.5.1(a) is

to be submitted to the responsible ABS Engineering Office for approval prior to conducting an implementation

survey. Only machinery subject to Special Continuous Survey of Machinery (CMS) is to be included in the

program (unless review of any non-essential machinery is specifically requested by the Owner).

5.3 Implementation Surveys

Once a plan has been reviewed/approved, an implementation survey is to be carried out by the attending

Surveyor prior to program commencement. The requirements for the implementation survey are provided

in 7-A-14/13.3 (for PM plans) or 7-A-14/15.3 (for CM plans).

Once this survey is carried out and the implementation found to be in order, a report confirming the

implementation of the Planned Maintenance and/or Condition Monitoring plan(s) is to be submitted by the

attending ABS Surveyor, and the plan(s) may be put into service.

5.5 Machinery Status Indicators

Once the Implementation Survey has been satisfactorily completed, the attending Surveyor shall advise

Classification Documentation Center (CDC) that the items covered by a Planned Maintenance plan as per

7-A-14/13.5.1(a)i) are to be shown by a PM indicator, and for the items covered by a Condition Monitoring

plan as per 7-A-14/15.5.1(a)i) are to be shown by a CM indicator. When equipment is covered by both PM

and CM plans, items covered are to be shown by a PM/CM indicator. The owner is to communicate with

the attending Surveyor to ensure that the Survey Manager for a vessel shows the correct indicators for all

listed equipment.

5.7 Cancellation of Program

The survey arrangement for machinery under the Preventative Maintenance Program may be cancelled by

ABS if the program is not being satisfactorily carried out, as a result of insufficient maintenance records,

lack of knowledge by the crew of the vessels program, the general condition of the machinery, or agreed

intervals between overhauls are exceeded resulting in the annual survey not being completed within the

survey window as required.

Sale, change of vessel management, change of Recognized Condition Monitoring Specialists, or transfer of

class is to be cause for reconsideration of the approval. If more than one occurs, the current plan will be

cancelled and a new plan will be required to be submitted for approval.

The Owner may cancel the survey arrangement for machinery under the Preventative Maintenance Program

by informing ABS in writing. For this case, items which have been inspected under the program since the

last Annual Survey may be credited for class at the discretion of the Surveyor.



7 Overhauls and Damage Repairs

7.1 Overhauls

For equipment enrolled in the Condition Monitoring plan, following an overhaul, new baseline data is to be

recorded in the presence of an ABS Recognized Condition Monitoring Company as soon as possible, but

not to exceed the next vibration signature period or six months and is to be included in the Annual Report.

Documentation on overhauls of items covered by the Preventative Maintenance Program is to be reported

and signed by the chief engineer.

7.3 Damage Repairs

All damage to components/machinery is to be reported to ABS. Repairs of damaged components/ machinery

are to be carried out to the satisfaction of the attending Surveyor in accordance with 7-1-1/7.1 and 7-1-1/7.3.

Any repair and corrective action regarding machinery under the Preventative Maintenance Program is to be

recorded and the repair verified by the attending Surveyor at the Annual Confirmation Survey. In the case of

overdue outstanding recommendations or a record of unrepaired damage which would affect the Preventative

Maintenance Program, the relevant items are to be removed from the program until the recommendation is

fulfilled or the repair is carried out.

9 Annual Surveys and Reporting

9.1 Annual Confirmation Surveys

Simultaneously with each Annual Survey of Machinery, for vessels enrolled in a Preventative Maintenance

Program, an Annual Confirmation Survey is to be performed by the attending Surveyor. The purpose of

this survey is to verify that the program is being correctly operated and that the machinery has been

functioning satisfactorily since the previous survey. The survey is to include the following:

i) A general examination of the items concerned is to be carried out.

ii) The Surveyor is to review the Owners annual report, as detailed in 7-A-14/9.3, and the required

onboard documentation as detailed in 7-A-14/11.

iii) The performance and maintenance records are to be examined to verify that the machinery has

functioned satisfactorily since the previous survey or action has been taken in response to machinery

operating parameters which are outside acceptable tolerances and the overhaul intervals have been

maintained.

iv) Written details of breakdowns or malfunctions of equipment are to be made available.

v) The description of repairs carried out is to be reviewed. Any machinery part, which has been replaced

with a spare due to damage is to be retained onboard, where possible, until examined by the attending

Surveyor.

vi) At the discretion of the Surveyor, operational function tests, testing of safety devices and/or trips,

confirmatory surveys and random check readings, are to be carried out as far as practicable and

reasonable.

Upon satisfactory completion of the above requirements, the Preventative Maintenance Program will be

accepted by ABS for its continued use. The Surveyor may credit to the current CMS cycle any of the listed

items that were overhauled and tested in the presence of and to the satisfaction of the attending Surveyor.

Additionally, any of the listed equipment items that have been overhauled in accordance with the Planned

Maintenance schedule may be credited to the CMS by the attending Surveyor after a satisfactory operational

test. Any machinery that has acceptable operating conditions as per the approved Condition Monitoring plan

may be credited to the current CMS cycle by the attending Surveyor after a satisfactory operational test.



9.3 Owners Annual Preventative Maintenance Report

The Annual Confirmation Survey of the Preventative Maintenance Program is to be carried out by the attending

Surveyor. The vessels qualified representative is to present an Annual Preventative Maintenance Report

via hard copy or approved alternative electronic formats (7-A-14/9.5) containing the information detailed

in 7-A-14/13.5.2 (for PM plans), 7-A-14/15.5.2 (for CM plans) and if applicable 7-A-14/17.7.2 (for RCM

programs) to the attending Surveyor for review and verification at the time of the Annual Confirmation

Survey of the Preventative Maintenance Program. Any reports submitted without all of the required information

will be returned without action to the submitter.

If the machinery included in the Preventative Maintenance Program has changed, this is to be stated. Any

machinery to be added to the program is subject to the requirements of 7-A-14/5, its respective section

[7-A-14/13.5 (for PM plans) or 7-A-14/15.5 (for CM plans)] and approval by the attending Surveyor.

When adding machinery to a Condition Monitoring plan, approval is required from the responsible ABS

Engineering Office. When removing machinery from any Preventative Maintenance Program, CDC is to

be advised and the machinery status updated accordingly.

9.5 Alternative Electronic Formats

Owners may opt to submit their annual reports to the attending Surveyor in a portable electronic format

(e.g., thumb drive, CD-ROM, or e-mail attachment), for review prior to or at the time of attendance onboard,

as required by 7-A-14/9. Acceptable file types are those which are compatible with MS Word, MS Excel,

and/or PDF. These reports must contain all the required information. In addition, the Owners must submit,

annually, in hard copy, the following to the attending Surveyor:

i) A letter stating that the annual report is on an alternative electronic format and meets the requirements

of format and file type as per 7-A-14/9.5.

ii) A summation and results of the annual vibration signatures. (For machinery enrolled in a Condition

Monitoring Plan)

iii) A summation and analysis of all unscheduled maintenance and breakdowns of the machinery enrolled

into the program.

iv) Directions on how to retrieve the report from the alternative electronic format.

11 Onboard Documentation

The vessels Chief Engineer shall be the responsible person onboard the vessel in charge of the Preventative

Maintenance Program. If a computerized system is used for updating the maintenance documentation and

maintenance program, access is to be permitted only by the Chief Engineer or other authorized persons.

Additional requirements are provided in 7-A-14/13.7 (for PM plans), 7-A-14/15.7 (for CM plans) or

7-A-14/17.9 (for RCM plans).

13 Planned Maintenance (PM)

13.1 General (2014)

Owners may conduct Planned Maintenance on any item(s) of equipment. However, the following equipment

cannot be enrolled into a PM plan and credit will not be given towards periodic surveys: x System Piping (All) x Valves (All) x Sea Chests x Bilge Pumps x Electrical Generators and associated Safety Devices and Trips (This does not include the prime mover or its attachments) x All Operational Tests



x Fire Pumps x Fire Fighting Equipment x Main Engine Crankpin and Crosshead bearings x Main Engine Turbochargers x Main Engine Safety Devices and Trips x Oily Water Separators x Air Receivers with associated Relief Valves and Safety Devices x Heat Exchangers and Unfired Pressure Vessels with design pressures over 6.9 bar (7kgf/cm2, 100 psi) and associated Relief Valves x Steering Gear Piping, Pumps and Control/Relief Valves x Steam Turbines x Anchor Windlass

13.3 PM Implementation Surveys

Owners are to submit a written request to enroll their vessel(s) in the Preventative Maintenance Program. Planned Maintenance plans are to be reviewed by the attending ABS Survey Office. Both the initial review and implementation survey can be conducted at the same time onboard the vessel(s). To complete the implementation survey, the following items need to be checked:

i) The onboard personnel are familiar with the PM Program

ii) The machinery identification method and record keeping procedures are to be described.

iii) The Preventative Maintenance Program is to be capable of producing the documentation required for the Annual Confirmation Survey (refer to 7-A-14/9 and 7-A-14/13.5.2) and required onboard documentation is present (see 7-A-14/11 and 7-A-14/13.7).

iv) The vessel is to comply with the requirements of surveys and testing for retention of class.

v) Details and back-up capabilities of the computerized system are to be reviewed.

vi) Owners will submit a comprehensive schedule of servicing and overhaul including a description of the work to be performed at each interval.

a) The proposed maintenance schedules are to be based upon the manufacturer recommended service and overhaul schedules. The vessel operator will submit a statement to ABS or show documentation that verifies that the proposed maintenance schedules are in accordance with manufacture recommendations.

b) If the proposed maintenance schedules are based on vessel operators previous experience due to lack of manufacturers information, then appropriate evidence supporting operators proposals are to be submitted for review.

vii) The PM Program is implemented according to the reviewed documentation and is adapted to the type and complexity of the components/systems on board.

viii) The Survey status for the vessel is to be reviewed by the attending Surveyor. The vessel is to be on Special Continuous Survey of Machinery (CMS). The Surveyor is to ascertain if there are any damages or open outstanding recommendations that would prevent the proposed equipment items from being allowed.

ix) The attending Surveyor will confirm, during the review, that the plan complies with the submission requirements of 7-A-14/13.5, including verification that machinery parts listed under 7-A-14/13 are not included. In addition, fire fighting appliances including breathing apparatus, fire extinguishers, firemans outfits and the international shore connection cannot be included under PM.

x) Where the Owners Preventative Maintenance Program includes both planned maintenance and condition monitoring, then the attending Surveyor will have to ensure that the condition monitoring details have been approved by the responsible ABS Engineering Office and comply with the requirements of 7-A-14/15.3.



13.5 Administrative Requirements

13.5.1 PM Plan Submission

13.5.1(a) For Items Covered by a Planned Maintenance Plan

i) A list and description of the machinery.

ii) Organization chart identifying areas of responsibility.

iii) Schedule of servicing and overhaul. This schedule is to meet at least the servicing and

overhaul intervals specified by the manufacturer and a statement to this effect is to accompany

the plan.

iv) Description of the work to be performed at each interval.

v) Machinery identification method and record keeping procedures.

vi) Planned maintenance sheet(s)/record(s) for each machine to be considered.

vii) A reference list showing owners equipment item name and ABS equivalent equipment

name as shown in ABS Survey Manager.

13.5.2 Owners Annual Preventative Maintenance Report Requirements

13.5.2(a) PM Plan Report Annual

i) A summary list of all machinery covered under the Planned Maintenance Program, including

a complete description of work completed on each machine since the last submitted

report. The Owner may add or delete equipment subject to the approval of the attending

ABS Surveyor, who is also to notify the ABS Classification and Documentation Center

(CDC) of any machinery additions or deletions, as necessary.

ii) Planned maintenance sheet(s)/record(s) for each machine.

iii) Exceptions, notes and comments noted during work.

iv) Modifications and justifications to the schedule, such as might be recommended by a

machinery manufacturers technical bulletin.

v) List of machines that failed prior to scheduled maintenance or servicing, and related record

of corrective actions taken.

If the machinery included in the Planned Maintenance plan has changed, this is to be stated. Any machinery

to be added to the plan is subject to the requirements of 7-A-14/13.5.1 and approval by the attending Surveyor.

The Owner is to advise the attending Surveyor of all machinery for which periodic maintenance is not

indicated or is incomplete as per the initial planned maintenance report. In the meantime, the condition of

the machinery is to be to the satisfaction of the attending Surveyor.

13.7 Onboard Documentation

13.7.1 PM Plan

i) The latest up-to-date information required in 7-A-14/13.5.1(a)

ii) A copy of the manufacturers service manuals and/or shipyards maintenance instructions

iii) Reference documentation (trend investigation procedures, etc.)

iv) All records showing compliance with the program (including repairs and renewals carried

out) are to be made available for review by the attending Surveyor at the Annual Survey

of Machinery.

v) A copy of the reviewed PM Plan

vi) A users manual for the Computerized Maintenance Management System



15 Condition Monitoring (CM)

A Condition Monitoring plan, which uses quarterly, semi-annual or annual measurements, is intended to be

supplemented with some Planned Maintenance activities. The benefit of using condition monitoring is that

it may extend the intervals on certain Planned Maintenance activities (e.g., replacement of parts which are

in good working order) based on the condition of the equipment at these periodic measurements. With

regards to vibration measurements, ABS principally allows two methods to be used towards the crediting

of the CMS cycle as discussed in 7-A-14/9.1. A summary of the first method involves the Chief Engineer

or other trained crewmember(s) collecting overall vibration data on a quarterly basis and a representative

specialist of an ABS Recognized Condition Monitoring Company collecting one set of complete vibration

signatures annually. A summary of the second method, discussed in 7-A-14/15.11, involves complete vibration

signatures being collected semi-annually by a representative specialist of an ABS Recognized Condition

Monitoring Company, with no requirement for data collection by the Chief Engineer or crewmembers. For

both methods, one set of complete vibration signatures is required to be taken during the three months prior

to the date that the Annual Preventative Maintenance Report is provided to the attending Surveyor.

When equipment is covered by both PM and CM plans (substantiated by a PM/CM indicator), the results

of the CM analysis may affect the requirements of the vessels PM plan. When the CM analysis demonstrates

that the equipment is operating satisfactorily, consideration will be given for deferring appropriate PM tasks.

15.1 General (2014)

Owners may conduct Condition Monitoring on any item(s) of equipment. However, the following equipment

cannot be enrolled into a CM plan and credit will not be given towards periodic surveys: x System Piping (All) x Valves (All) x Sea Chests x Bilge Pumps x Electrical Generators and associated Safety Devices and Trips (This does not include the prime mover or its attachments) x All Operational Tests x Fire Pumps x Fire Fighting Equipment x Main Engine Safety Devices and Trips x Oily Water Separators x Air Receivers with associated Relief Valves and Safety Devices x Heat Exchangers and Unfired Pressure Vessels with design pressures over 6.9 bar (7 kgf/cm2, 100 psi) and associated Relief Valves x Steering Gear Piping, Pumps and Control/Relief Valves x Anchor Windlass

15.3 CM Implementation Surveys

Owners are to submit a written request to enroll their vessel(s) in the Preventative Maintenance Program.

Condition Monitoring plans are to be approved by the responsible ABS Engineering Office. The plan must

be approved before an implementation survey can be conducted. To complete the implementation survey,

the following items need to be checked:



i) The CM Program is implemented according to the approved documentation and is adapted to the

type and complexity of the components/systems on board

ii) The onboard personnel are familiar with the CM Program

iii) The machinery identification method and record keeping procedures are to be described.

iv) The Preventative Maintenance Program must be capable of producing the documentation required

for the Annual Confirmation Survey (refer to 7-A-14/9 and 7-A-14/15.5.2) and required onboard

documentation is present (7-A-14/11 and 7-A-14/15.7).

v) Details and back-up capabilities of the computerized system are to be reviewed.

vi) The vessel is able to comply with the requirements of surveys and testing for retention of class.

vii) The Survey status for the vessel is to be reviewed by the attending Surveyor. The vessel is to be

on Special Continuous Survey of Machinery (CMS). The Surveyor is to ascertain if there are any

damages or open outstanding recommendations that would prevent the proposed equipment items

from being allowed.

viii) The attending Surveyor will confirm, during the review, that the plan complies with the submission

requirements of 7-A-14/15.5, including verification that machinery parts listed under 7-A-14/15

are not included. In addition, fire fighting appliances including breathing apparatus, fire extinguishers,

firemans outfits and the international shore connection cannot be included under CM.


15.5.1 CM Plan Submission

15.5.1(a) For Items Covered by a Condition Monitoring Plan

i) A list and description of the machinery covered including:

a) Method of data collection and analysis tools

b) Nominal rpm

c) Horsepower

d) Location and orientation of sensor attachments, which are to be permanently marked

and/or affixed by a Recognized Condition Monitoring Specialist on covered

machinery

e) Sampling procedures for oil analysis

ii) Organization chart identifying areas of responsibility.

iii) Schedule of data collection.

iv) Type and model of data collection instrument, including sensor and attachment method

and calibration schedule.

v) Acceptance criteria of data.

vi) Baseline data. Initial or baseline data are to be recorded in the presence of the Surveyor

and/or a representative specialist of an ABS Recognized Condition Monitoring Company

and are to be compared to the acceptable vibration levels shown in SNAMEs T&R Bulletin

3-42 Guidelines for the Use of Vibration Monitoring for Preventative Maintenance or

other equivalent national or international standards. The Owner is to be notified of all

machinery that does not meet acceptance criteria (i.e., machinery with high vibration levels).

vii) A reference list showing owners equipment item name and ABS equivalent equipment




15.5.2 Owners Annual Preventative Maintenance Report Requirements

15.5.2(a) CM Plan Report Annual

i) A summary report listing all machinery covered under the Condition Monitoring plan, clearly

stating the overall condition of the machinery based on the most recent vibration measurement

data (i.e., Satisfactory, Marginal, or Unacceptable). Data for the report must have been

collected within three months of the submission date of the report by an ABS Recognized

Condition Monitoring Company. This report is to be provided to the attending Surveyor.

ii) Where the crew is taking vibration measurements, then training records for the designated

crew members and description of training is to be included. Also, the type of recording

device, method of data collection and calibration of the data collector must be provided. See

also. The attending Surveyor may request a trained crewmember to demonstrate proficiency

in vibration reading and related management of the obtained data.

iii) Summary and analysis of machines that failed prior to a vibration reading or servicing.

iv) Records of any maintenance conducted on equipment enrolled in the CM Plan.

v) Records of any equipment that has been replaced, including information required by

7-A-14/15.5.1(a).

If the machinery included in the Condition Monitoring plan has changed, this is to be stated. Any machinery

to be added to the plan is subject to the requirements of 7-A-14/15.5.1 approval by the responsible ABS

Engineering Office and the attending Surveyor. Any machinery to be deleted from the Condition Monitoring

plan is to be brought to the attention of the attending Surveyor and written documentation sent to the

responsible ABS Engineering Office and CDC.

Vibration readings are to be compared to the baseline readings in the implementation report. The Owner is

to advise the attending Surveyor of required maintenance or additional monitoring which is needed for

machinery with vibration readings above those in the approved baseline. Machinery unavailable for

measurements are to be noted and the Owner advised that readings are to be submitted for review. In the

meantime, the condition of the machinery is to be to the satisfaction of the attending Surveyor.


15.7.1 CM Plan

i) The latest up-to-date information required in 7-A-14/15.5.1(a).

ii) For vessels with onboard vibration meters or FFT vibration analyzers, manuals supplied

by manufacturers for use of data collectors and computer programs, as well as guidance

for machine operating and diagnosis of machine faults.

iii) Condition monitoring data, including all data since last opening of the machine and the

original baseline data.

a) Complete vibration data (including vibration signatures), as specified in

7-A-14/15.5.1(a), are to be taken and reviewed by a representative of an ABS

Recognized Condition Monitoring Company on an annual basis or more frequently

when warranted by abnormal conditions or operational parameters, and retained

onboard for review by the attending Surveyor.

b) Full trend analysis (including spectral analysis for vibration) of machinery displaying

operating parameters exceeding acceptable tolerances. Also, alarm criteria.

c) Relevant operational data during data recording, such as sea state, machine

temperature, other equipment affecting the data, etc. are to be included.

d) Quarterly overall broadband vibration meter readings recorded by vessel personnel

(or documentation showing alternative techniques are approved) and retained

onboard for review by the attending Surveyor.

iv) Reference documentation (trend investigation procedures, etc.).



v) Records of lube oil analysis, rotor positioning readings, and interstage bleed system pressures

are to be recorded by the vessels personnel at least on a quarterly basis and retained onboard

for review annually by the attending Surveyor.

vi) If the vessel includes internal combustion engines in the program, the data outlined in

7-A-14/15.9.2 must be retained onboard for review annually by the attending Surveyor.

vii) Calibration date of equipment. Calibration is to be in accordance with the manufacturers

recommendations or annually, if not otherwise specified.

viii) Crew training records of the designated members, where crew is taking periodic vibration

readings.

ix) Any repairs or changes to any machines must be reported, and a summation and analysis

of all unscheduled maintenance and/or breakdowns of monitored equipment.

x) All records showing compliance with the program, including a copy of the most recent

Owners annual report are to be made available for review by the Surveyor at the Annual

Survey of Machinery.

xi) A copy of the approved CM Plan and ABS approval letter

xii) A users manual for the Computerized Maintenance Management System

15.9 Special Conditions

15.9.1 Steam Turbine

Condition monitoring of turbines must provide information as per 7-A-14/11.

The main propulsion turbine rotor journal bearings, thrust bearings, and flexible couplings are to

be opened up for examination. The low pressure exhaust trunk is to be opened for examination of the

last row of low pressure and astern wheels. Providing vibration readings, lubrication oil analysis and

axial rotor position checks and turbine operating records are reviewed and all considered satisfactory

by the Surveyor, the lifting of the main propulsion turbine casings (HP and LP) may be waived at

alternate, subsequent Special Periodical Surveys, as outlined in 7-6-2/3.1.4.

On turbines where variable or abnormal readings are noted, readings are to be recorded by the

vessels personnel more frequently, as appropriate to properly monitor the performance range or

establish the trend.

15.9.2 Internal Combustion Engines

Machine condition monitoring of internal combustion engines must provide a detailed engine analysis,

as well as information provided in 7-A-14/5.1. The following data must be recorded at least monthly,

unless indicated otherwise.

i) Operating time (running hours)

ii) Power output (MCR)

iii) RPM

iv) Cylinder pressure as function of crank angle

v) Injection pressure as function of crank angle

vi) Cylinder liner and piston ring wear (on basis of compression/firing pressures or proximity

readings)

vii) Scavenging air pressures and temperatures

viii) Lubricating oil and cylinder oil consumption

ix) Bearing temperatures (main, crank pin, crosshead and internal thrust, as fitted)

x) Cylinder exhaust temperatures

xi) Turbocharger vibration and T/C RPM



xii) Lubricating oil analysis (quarterly)

xiii) Crankshaft deflection readings for medium/slow speed diesel engines, as defined in 4-2-1/1.3

of the ABS Rules for Building and Classing Steel Vessels (quarterly).

For machines for which variable or abnormal readings are noted, readings are to be recorded by the

vessels personnel more frequently, as appropriate to properly monitor the performance range or

establish the trend.

15.9.3 Electrical Switch Gear and Power Distribution Panels

Condition monitoring plans for electrical equipment are to include examination of panels,

switchboards, transformers and other essential electrical apparatus by infrared photographic

thermography during each five-year survey cycle while the circuit is energized and under normal

workloads. A report describing the results of the survey, as well as periodic insulation resistance

records must be retained onboard for review by the attending ABS Surveyor.

15.9.4 Diesel Engine Bearing Wear Monitoring Systems (2014)

Condition Monitoring plans for bearing wear monitoring systems apply to main, crosshead and

crank pin bearings. The bearing wear monitoring system may be credited towards CMS under the

Condition Monitoring plan, in lieu of the required bearing open out method. In order for ABS to

accept this alternative to main diesel engine bearing open out inspections, the following minimum

requirements have been established for implementing a bearing wear monitoring system:

i) The Owner is to submit a written request to the responsible ABS Engineering Office to

review details of the system to be installed and vessel(s) on which the system is to be fitted.

ii) The bearing wear monitoring system is to be ABS Type Approved.

iii) Owner is to provide a letter from the engine manufacturer confirming, for the engine model

installed, that the specified bearing monitoring system eliminates the need for normal

opening of the bearings for inspections and listing the specific bearings that are covered.

iv) Engine bearings are placed under Condition Monitoring status and an implementation survey

is required.

v) Vessel's Chief Engineer is responsible for maintaining records of trend measurements

from established initial base line value. Therefore, appropriate records are to be available

for examination by the attending Surveyor during surveys.

vi) The attending Surveyor will retain the option to require (partial or full) opening of a bearing

where the bearing condition analysis suggests abnormalities, based on external examination,

feeler gauge readings, bearing edge condition, oil analysis results, or crank shaft deflections,

etc.

For crosshead bearings enrolled in this plan, one crosshead bearing is to be opened out for

inspection during each Special Survey cycle. If problems are found, then further openings

may be required. Owners are encouraged to open these bearings during drydocking periods

whenever possible.

15.9.5 Permanently Installed Monitoring Equipment

Permanently installed electronic analyzing equipment used for the Condition Monitoring Program is to

comply with the requirements of 4-9-3/17 of the ABS Rules for Building and Classing Steel Vessels,

regarding testing and certification of automatic and remote control systems for use onboard ship.



15.11 Alternative Techniques

Application of techniques of condition monitoring other than those mentioned above will be specially

considered.

15.11.1 Semi-Annual Alternative (2014)

Condition monitoring based on semi-annual signatures is acceptable as an alternative technique for

rotating machinery in lieu of quarterly overall vibration meter readings supplemented by an annual

signature, as required in 7-A-14/15.7.1iii). The semi-annual signatures are to be taken and reviewed

by a representative of an ABS Recognized Condition Monitoring Company. External checks, such

as lube oil analysis, shaft position indicating and bearing temperatures are not affected and are to

continue to be monitored by the crew at least on a quarterly basis.

The annual Owners report is to clearly indicate that this alternative is being utilized and must include

both semi-annual signatures for all of the monitored equipment. In addition, a summation and

analysis of all unscheduled maintenance and/or breakdowns of the monitored equipment which were

not identified by the semi-annual signatures must be included. Any reports submitted without the

required statement of maintenance and/or summation will be returned without action to the submitter.

17 Reliability Centered Maintenance (RCM)

17.1 Application

The following are procedures and conditions under which a properly conducted Reliability Centered

Maintenance (RCM) analysis and the resulting Preventative Maintenance Program may be credited as

satisfying the requirements of Special Continuous Survey of Machinery.

No preventative maintenance plan supersedes the judgment of an ABS Surveyor, nor does it waive an ABS

Surveyor(s) attendance for damage, overhaul of main engines, generator engines, steering gears, general

insulation condition and resistance tests, electrical devices functional tests, reduction gear teeth examinations,

hydrostatic tests of pressure vessels, tests and verification of safety devices such as relief valves, overspeed

trips, emergency shut-offs, low-oil pressure trips, etc., as required by the ABS Rules for Building and

Classing Steel Vessels, including the ABS Rules for Survey After Construction (Part 7).It is a prerequisite

that the machinery in this program be on a Special Continuous Survey of Machinery (CMS) cycle.

17.3 General

By using RCM principles, maintenance is evaluated and applied in a rational manner. Functional failures

with the highest risk are identified and then focused on. Equipment items and their failure modes that will

cause high-risk functional failures are identified for further analyses. Maintenance tasks and maintenance

strategies that will reduce risk to acceptable levels are determined. Spare parts inventories are determined based

on the maintenance tasks developed and a risk assessment. An RCM sustainment procedure is instituted to

continually monitor and optimize maintenance. Accordingly, improved equipment and system reliability

can be expected.

Additional information and explanations on how to develop a RCM program can be found in the ABS

Guide for Survey Based on Reliability Centered Maintenance (RCM Survey Guide), and the ABS Guidance

Notes on Reliability Centered Maintenance (RCM Guidance Notes).

17.3.1 Definitions

A RCM analysis as defined by the RCM Guidance Notes will generate additional types of maintenance

tasks which are not previously defined by the Preventative Maintenance Program. In order to

simplify the RCM Program plan approval process, implementation survey and annual surveys, the

following groupings of these tasks will be used to determine the applicable requirements:

i) Planned Maintenance type-tasks x Planned Maintenance Tasks x Failure Finding Tasks x Other Applicable and Effective Tasks



ii) Condition Monitoring type-tasks x Condition Monitoring Tasks x Combinations of Planned Maintenance and Conditioning Monitoring Tasks 17.3.2 Optional Notations

The RCM Program is to be approved by an ABS Engineering Office. Upon completion of a

satisfactory Implementation Survey, a Certificate of Approval for Reliability Centered Maintenance

Program is to be issued by the attending Surveyor. A notation, if appropriate, will be entered in

the Record. The Owner may select desired systems or equipment items for which a RCM analysis

will be conducted and will be used to develop a Preventative Maintenance Program. All machinery

items covered by the RCM analysis will be surveyed and credited in accordance with the ABS

Rules for Survey After Construction (Part 7) and the respective section(s) of the Preventative

Maintenance Program.

When the RCM Program is approved for the equipment related to:

i) The propulsion system, including as applicable: prime mover(s), reduction gears, shafting,

propeller or other thrusting device, all auxiliary systems providing, cooling, control, electrical

power, exhaust, fuel, lubrication and equipment related to the steering or other directional

control system, the RCM Program will be assigned and distinguished in the Record with

the class notation RCM (PROP).

ii) The cargo handling (cargo pumps, associated piping for internal and independent tanks)

and safety equipment (i.e., inert gas system, vapor emission control) for a tanker, liquefied

gas carrier or chemical carrier, the RCM Program will be assigned and distinguished in

the Record with the class notation RCM (CARGO).

iii) Systems used in connection with drilling, when the drilling system is in compliance with

the ABS Guide for the Classification of Drilling Systems, will be distinguished in the

Record with the class notation RCM (CDS).

iv) (2014) When the RCM Program is approved for the Production or Facilities systems and

equipment on an FPSO or FSO, the RCM Program will be distinguished in the Record

with the class notation RCM (PFE).

17.3.3 Survey Credit Towards the Current CMS Cycle.

Owners may conduct a RCM analysis on any item(s) of equipment, but credit will only be given

towards periodic surveys when the equipment and associated Preventative Maintenance tasks (as

defined in 7-A-14/17.3.1) are in compliance with the applicable requirements stated in 7-A-14/13

and/or 7-A-14/15.

17.5 RCM Implementation Surveys

Owners are to submit a written request to enroll their vessel(s) in the Reliability Centered Maintenance (RCM)

Program. RCM plans are to be approved by the responsible ABS Engineering Office. The plan must be

approved before an implementation survey can be conducted. To complete the implementation survey, the

following items need to be checked:

i) The RCM Program is implemented according to the approved documentation and is adapted to the

type and complexity of the components/systems on board.

ii) The onboard personnel are familiar with the RCM Program.

iii) The machinery identification method and record keeping procedures are described and implemented.

iv) The onboard RCM software must be capable of producing the documentation required for the Annual

Confirmation Survey (refer to 7-A-14/9 and 7-A-14/17.7.2) and required onboard documentation

is present (7-A-14/11 and 7-A-14/17.9).

v) A Spare Parts list is readily available and the crew knows how to find parts using it.

vi) A RCM sustainment process is in effect which supports the RCM analysis and future updates.



vii) Details and back-up capabilities of the computerized system are to be reviewed.

viii) The vessel is able to comply with the requirements of surveys and testing for retention of class.

ix) The Survey status for the vessel is to be reviewed by the attending Surveyor. The vessel is to be

on Special Continuous Survey of Machinery (CMS). The Surveyor is to ascertain if there are any

damages or open outstanding recommendations that would prevent the proposed equipment items

from being allowed.

x) The attending Surveyor will confirm, during the review, that the plan complies with the submission

requirements of 7-A-14/17.7, including verification that machinery parts listed under 7-A-14/13

(or 7-A-14/15 if applicable) are not included. In addition, fire fighting appliances including breathing

apparatus, fire extinguishers, firemans outfits and the international shore connection cannot be

included under RCM.

xi) For vessels that are due to be placed in service or have recently been delivered so that little or no

scheduled maintenance has been performed, the Surveyor is to verify items i), iii), iv), v), vi) are

available and the onboard personnel have been trained to implement the RCM Program, item ii).


17.7.1 Items Required for RCM Program Submission

i) Define Systems

ii) Identify Functions and functional failure

iii) Conduct Failure Modes, Effects, and Criticality Analysis

iv) Select a failure management strategy

v) Develop a Preventative Maintenance Program plan

vi) Develop a spare parts holding plan [refer to 7-A-14/17.7.1(a)]

vii) Develop a RCM sustainment plan [refer to 7-A-14/17.7.1(b)]

viii) Document and submit the analysis and plans.

ix) A reference list showing owners equipment item name and ABS equivalent equipment


17.7.1(a) Spare Parts Holding Documentation. The spare parts holding documentation is to be a

summary. The documentation is to provide the following information:

i) There is to be identification between the maintenance task listed and the RCM analysis

(e.g., Item Nos. in the RCM analysis).

ii) The task type is to be listed (e.g., Condition Monitoring (CM), Planned Maintenance (PM),

Combination of CM and PM (CM/PM), Failure Finding (FF), One-time Change (OTC),

Run-to- Failure (RTF), Any Applicable and Effective Task (AAET).

iii) The risk due to a spare being out of stock, along with the appropriate spare parts strategy

(e.g., Order parts before demand, Hold parts in storage, Revise RCM maintenance tasks,

Review RCM maintenance tasks, No spares holdings required).

iv) The maintenance procedure is listed.

An example of a Spare Parts Holding Determination summary is shown in Section 2, Table 10 of

the RCM Survey Guide.

17.7.1(b) RCM Sustainment Documentation. The sustainment documentation is to be maintained

onboard by the vessel/rig/facility operators. The sustainment process is to be designed to allow

verification by the attending Surveyor at the annual Survey. Sustainment documentation is to

include the following items:



i) Trend Analysis

ii) Maintenance Requirement Document Reviews

iii) Task-packaging Reviews

iv) Age-exploration Tasks

v) Failures

vi) Relative Ranking Analysis

vii) Other Activities

17.7.2 Owners Annual RCM Program Report Requirements

The Annual Confirmation of the Reliability Centered Maintenance Program will be carried out by

the attending Surveyor, who will confirm the Program is being effectively implemented onboard.

The vessels Owner or qualified representative is to present an Annual Reliability Centered

Maintenance Report containing the following information to the attending Surveyor for review

and verification at the time of the Annual Confirmation Survey. Any reports submitted without all

of the required information will be returned without action to the submitter. The annual report is to

be submitted in an electronic format in accordance with the requirements of 7-A-14/9.5. Information

to be included with the annual report is detailed in the following:

i) If equipment items included in the Reliability Centered Maintenance Program are to be

changed, this is to be stated. Any machinery to be added to the system will require approval

by the responsible ABS Engineering Office and the attending Surveyor with appropriate

notification sent to CDC. Any machinery to be deleted from the RCM Program is to be

brought to the attention of the attending Surveyor and written documentation sent to the

responsible ABS Engineering Office and CDC.

ii) If during the sustainment process it was determined that the time interval for any Planned

Maintenance type-task needs to be altered, then changes will need to be submitted with

documentation that supports the change in interval to the attending Surveyor for review

and acknowledgement.

iii) All Planned Maintenance type-tasks As per the requirements of 7-A-14/13.5.2(a)

iv) All Condition Monitoring typetasks As per the requirements of 7-A-14/15.5.2(a)

v) RCM Sustainment Activities Evidence of sustainment activities are to be included in the

annual report. The results of relative ranking analyses, trend analyses, maintenance

requirements document reviews, task packaging reviews, age exploration tasks and failure

investigations of all unscheduled maintenance and/or breakdowns are to be provided.

Sustainment activities can be conducted ashore as long as some shipboard personnel, who

have been participating in the RCM program aboard the subject vessel, are involved in the

sustainment activities. Appropriate documentation can also be produced ashore but will be

required to be present in addition to normally required onboard documentation during the

annual confirmation survey.

vi) Report Exceptions The Owner is to advise the attending Surveyor of all machinery for

which maintenance is not indicated or is incomplete as per the implementation report or

when additional monitoring is needed for machinery with vibration readings above those in

the approved baseline. If either of the above mentioned situations occurs, the condition of

the machinery is to be to the satisfaction of the attending Surveyor.


The vessels Chief Engineer shall be the responsible person onboard, and in charge of the Reliability Centered

Maintenance Program. If a computerized system is used for updating the maintenance documentation and

maintenance program, access is to be permitted only by the Chief Engineer or other authorized persons.

The following information is to be available onboard.



i) The latest up-to-date information required in 7-A-14/15.5.1(a).

ii) For vessels with onboard vibration meters or FFT vibration analyzers, manuals supplied by

manufacturers for use of data collectors and computer programs, as well as guidance for machine

operating and diagnosis of machine faults.

iii) Condition monitoring data, including all data since last opening of the machine and the original

baseline data.

iv) Reference documentation (trend investigation procedures, etc.).

v) Records of lube oil analysis, rotor positioning readings, and interstage bleed system pressures are

to be recorded by the vessels personnel at least on a quarterly basis and retained onboard for

review annually by the attending Surveyor.

vi) Complete vibration data, as specified in 7-A-14/15.5.1(a), are to be taken at least quarterly, or

more frequently when warranted by abnormal conditions and operational parameters, and to be

reviewed by a representative specialist of an ABS Recognized Condition Monitoring Company

and retained onboard for review annually by the attending Surveyor.

vii) If the vessel includes internal combustion engines in the program, the data outlined in 7-A-14/15.9.2

must be retained onboard for review annually by the attending Surveyor.

viii) Calibration date of equipment. Calibration is to be in accordance with the manufacturers

recommendations or annually, if not otherwise specified.

ix) Any repairs or changes to any machines must be reported, and a summation and analysis of all

unscheduled maintenance and/or breakdowns of monitored equipment.

x) All records showing compliance with the program, including a copy of the most recent Owners

annual report are to be made available for review by the Surveyor at the Annual Survey of Machinery.

xi) Crew training records of the designated members, where crew is taking periodic vibration readings.

xii) Records for required spare parts, inventory and ordering procedures to procure additional spare

parts are to be readily available.

xiii) Records of sustainment activities are to be readily available, refer to 7-A-14/17.7.1(b).

xiv) A copy of the approved RCM Plan and ABS approval letter

xv) A users manual for the Computerized Maintenance Management System

19 Information

For information on becoming an ABS External Specialist, please contact:

American Bureau of Shipping

16855 Northchase Drive

Houston, TX 77060-6008

Attn: External Specialist Coordinator

Telephone: 281-877-5971

Fax: 281-877-6012

21 ABS Offices Responsible for PMP and RCM

ABS Americas

ABS Americas Division

16855 Northchase Drive

Houston, TX 77060-6008

Attn: Manager, Houston SED Ship Machinery & Systems



ABS Europe

ABS Europe Ltd.

No. 1 Frying Pan Alley

London, E1 7HR, United Kingdom

Attn: Manager, Engineering

ABS Pacific

ABS Pacific Division

Urban Square Yokohama

4th/9th Floor

1-1 Sakae-Cho

Kanagawa-Ku

Yokohama 221-0052, Japan

Attn: Manager, Engineering Services, Machinery, Electrical & Control Systems

ABS Greater China

ABS Greater China Division

5th Floor

Silver Tower

No. 85 Taoyuan Road

Luwan District

Shanghai, 200021 P.R. China

Attn: Manager, Engineering Services

PSM w ABS

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